Switchgear Load Sharing for Fluctuating Fracturing Pump Demand

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Solution Overview

Problem

Hydraulic fracturing operations face challenges in managing fluctuating power demands due to unpredictable wellhead pressure and fluid rate variations, making it difficult to maintain steady turbine output and leading to inefficiencies and potential equipment failure.

Innovation Solution

A method and system for electrical load sharing between switchgear trailers acting as power hubs, utilizing a tie breaker to distribute power between multiple generators, allowing for flexible operation modes that balance load distribution and redundancy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple turbine generators are used to power hydraulic fracturing operations, then power availability and operational flexibility improve, but system complexity and equipment footprint increase

Engineering Contradiction:

Improvepower availabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple turbine generators and switchgear units into an integrated power system where components share loads collectively. The switchgear units are merged into a common electrical network that allows automatic load redistribution, reducing the need for separate redundant systems while maintaining power availability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Each switchgear unit is designed to perform multiple functions: normal power distribution, automatic load sharing when generators are offline, and system isolation during faults. This multi-functionality reduces the need for dedicated backup equipment, simplifying the overall system while improving adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If turbine generators operate at varying loads to match fluctuating power demands, then system adaptability improves, but operational efficiency and turbine lifespan decrease

Engineering Contradiction:

Improvesystem adaptabilityVSAvoidoperational efficiency

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The system incorporates automatic load sharing control that continuously monitors generator output and switchgear status. When a generator goes offline or load changes occur, the control system automatically redistributes loads among remaining units, maintaining optimal operating points and preventing inefficient partial-loading conditions.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The switchgear units dynamically adjust their load distribution in real-time based on generator availability and power demand. This dynamic load sharing allows turbines to operate at more consistent, efficient loads while the system adapts to changing conditions through automatic reconfiguration rather than manual intervention.

Inventive Principle:

Principle #15Dynamics

3Reliability

If redundant power generation capacity is maintained for reliability, then system reliability improves, but equipment footprint and initial investment increase

Engineering Contradiction:

Improvesystem reliabilityVSAvoidequipment footprint

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent merges multiple switchgear units into a shared electrical network that provides inherent redundancy through load sharing capabilities. When one generator or switchgear unit fails, the system automatically redistributes loads among remaining components, providing reliability without requiring separate dedicated backup equipment, thus reducing equipment footprint.

Inventive Principle:

Principle #5Merging (Combining)

4Power

If diesel engines are used for fracturing operations, then power delivery and operational control improve, but environmental impact and operational safety worsen

Engineering Contradiction:

Improvepower deliveryVSAvoidenvironmental impact

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The patent replaces diesel mechanical engines with electrical turbine generators powered by natural gas. This substitution eliminates diesel combustion, removing associated environmental harms (exhaust emissions, pollutants) and safety risks (fuel leaks, fires) while maintaining power delivery capabilities through the electrical power system and switchgear infrastructure.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12555984B2Switchgear load sharing for oil field equipment

Publication Date: 2026.02.17 US WELL SERVICES LLC

AI summary

A hydraulic fracturing system for fracturing a subterranean formation is disclosed. In an embodiment, the system may include a plurality of electric pumps fluidly connected to a well associated with the subterranean formation and powered by at least one electric motor, and configured to pump fluid into a wellbore associated with the well at a high pressure so that the fluid passes from the wellbore into the subterranean formation and fractures the subterranean formation; at least one generator electrically coupled to the plurality of electric pumps so as to generate electricity for use by the plurality of electric pumps; and at least one switchgear electrically coupled to the at least one generator and configured to distribute an electrical load between the plurality of electric pumps and the at least one generator.